Pilot-Scale Electrospinning of PLA Using Biobased Dyes as Multifunctional Additives

Abstract

Fibers with diameters in the lower micrometer range have unique properties suitable for applications in the textile and biomedical industries. Such fibers are usually produced by solution electrospinning, but this process is environmentally harmful because it requires the use of toxic solvents. Melt electrospinning is a sustainable alternative but the high viscosity and low electrical conductivity of molten polymers produce thicker fibers. Here, we used multifunctional biobased dyes as additives to improve the spinnability of polylactic acid (PLA), improving the spinnability by reducing the electrical resistance of the melt, and incorporating antibacterial activity against Staphylococcus aureus. Spinning trials using our 600-nozzle pilot-scale melt-electrospinning device showed that the addition of dyes produced narrower fibers in the resulting fiber web, with a minimum diameter of ~9 µm for the fiber containing 3% (w/w) of curcumin. The reduction in diameter was low at lower throughputs but more significant at higher throughputs, where the diameter reduced from 46 µm to approximately 23 µm. Although all three dyes showed antibacterial activity, only the PLA melt containing 5% (w/w) curcumin retained this property in the fiber web. Our results provide the basis for the development of environmentally friendly melt-electrospinning processes for the pilot-scale manufacturing of microfibers.

Pilot-Scale Melt Electrospinning of Polybutylene Succinate Fiber Mats for a Biobased and Biodegradable Face Mask

“…With greater distance between the nozzle and collector, the fiber diameter increased due to the lower electric field strength, which limited interactions between the polymer jet and electric field [30]. Similar observations have been made by researchers in the past where increasing the nozzle-to-collector distance during the melt-electrospinning of PLA led to an increase in fiber diameter [20]. At higher electric field strengths (−40 and −45 kV), nozzle-to-collector distances of 3-5 cm resulted in short circuits, observed as flashes between the nozzle and collector, indicating that the electric field strength was high enough for electrons to jump directly from one side to the other.…”

“…Melt electrospinning is a more efficient process and there is no need for any solvents, making it a more environmentally sustainable alternative [14]. Research has therefore focused on optimizing the melt-electrospinning process to produce nanoscale fibers, especially from biobased and biodegradable polymers [18][19][20][21][22][23][24].…”

Alizarin old and new: Extraction techniques for coloration, advances in detection methods for historical textiles and novel applications as a functional dye

“…Antibacterial activities of alizarin against A, Escherichia coli , and B, Staphylococcus aureus , reused from Ref 160 159 .…”

“…I G U R E 6 Antibacterial activities of alizarin against A, Escherichia coli, and B, Staphylococcus aureus, reused from Ref 160. ; C, Effect of alizarin on the hyphal growth of Candida albicans, reused from Ref 159.…”

Preparation and Antibacterial Properties of PLA-Based Composite Nanofiber Membrane Material Loaded with Cationic Antibacterial Agent by Electrospinning

“…Meanwhile, PLA-based nanofiber membranes are widely used in the textile industry as antibacterial materials [14]. Silver, a natural antibiotic, is also commonly used as an antimicrobial agent [15].…”